< Previous20 Food & Drink International www.fdiforum.net PACKAGING SPOTLIGHT Make, use, repeat Do you need your products to be made in recycled plastic? With the focus on recycling plastic high on the agenda, Measom Freer has successfully trialled the use of black recycled polypropylene in its injection moulded products. The plastic is extracted from recycled vehicle batteries and although the material is not food approved, it is suitable for re-use in industrial and other sectors. Measom Freer can manufacture to order any of their stock measures 05 – 150ml, scoops small to large, spatulas, fasteners, a wide variety of closures including screw, tall, spouted, luer, dropper and nozzle caps and tubes in this material. Recently accredited with BSI ISO14001 in Environmental Management, you can rely on Measom Freer to put the environment at its heart and supply a recycled product that your customer will love, and they can recycle it again after they have used it. For more information, visit www.measomfreer.co.uk. maintained that plastic packaging is necessary for preserving the integrity of fresh produce, a report from the Australian Fresh Produce Alliance has added academic weight to the argument. The report, undertaken on behalf of RMIT University in Melbourne and eco-software design company Empauer, shows that fresh produce packaging can help mitigate the estimated $10 million worth of food lost or wasted in Australia each year. The findings, which can be applied globally, show the benefits of packaging for fresh produce include product protection, extension of shelf life and the ability to communicate product information which assists customers in purchasing decisions. The example given was punnets used to package fresh berries. In this example, the report found the environmental impact of waste generated from damaged, unsellable fruit outweighed the impact of utilising the punnet. So based on these results, simply removing packaging from the supply chain isn’t an environmental cure all. Instead, the emphasis should be on creating more sustainable, eco-friendly and, crucially, recyclable packaging. Yet there’s no denying that fresh produce is an area which needs to lower its reliance on plastic packaging. One of the most exciting solutions in this regard is edible coatings, which can be applied on the surface of fruits and vegetables. Not only do they help to protect produce in transit, but they also reduce spoilage, boosting shelf life and helping to curb food waste. Food waste and recyclability are both, of course, having an impact on the food and drink industry, but one of the most profound changes comes in the form of plain packaging, often touted as a means of reducing the consumption of high salt, fat and sugar products – especially sugary soft drinks and alcohol. It’s been posited in parliament, by action groups and campaigners that using plain packaging for high sugar beverages and alcohol – similar to the plain packaging for cigarettes and tobacco products introduced in the UK in 2016 – would help to curb the obesity crisis and levels of heart disease, stroke and diabetes. However, a report from consultancy company, Brand Finance, found that the global beverage industry could stand to lose as much as $400 billion if plain packaging were extended to sugary drinks and alcohol. There has also been calls for plain packaging to be extended to snack foods, presenting an existential threat for the food and drink industry. Product launches are increasing, shelf space is at a premium and start-ups and artisan produces are emerging to take on and disrupt major brands. Producers 23 Á © Shutterstock/ Aumm graphixphoto 18-23.qxp_Layout 1 22/10/2019 13:23 Page 3Food & Drink International 21 www.fdiforum.net PACKAGING SPOTLIGHT Stainless steel conveyor systems Stand alone units or fully integrated Robotic and end of line equipment Bespoke engineering capabilities Turnkey and standalone solutions Integration and project management Service support and upgrades Partnered with Lita Palletising Systems for over 30 years www.kensal.com sales@kensal.com | tel: +44 (0) 1 582 425 777 Kensal Handling Systems Ltd, Kensal House, President Way, Luton, LU2 9NR Embracing the latest technology, Kensal consistently delivers improved line efficiency for customers, whilst reducing operating costs. Handling a Better Solution SICK goes flat out for sub-miniature performance With the launch of its G2 Flat family of photoelectric sensors, SICK has shrunk outstanding performance into a miniature format. The ultra-thin sensors are designed to integrate snugly into small machinery and conveyors, or for tight fits in robotic arms and grippers, for example in end-of-line packaging applications. Starting at just 3.5mm thick, the SICK G2 Flat family of proximity and through-beam sensors achieve highly-reliable detection of objects of almost any size, thanks to the unrivalled precision of SICK’s PinPoint visible laser light spot technology, even for jet-black, transparent, mirrored or shiny surfaces. The SICK G2 Flat photoelectric proximity sensor impresses with unrivalled background suppression capability to detect objects down to 0.1mm in size at distances as small as 8mm. The SICK G2 Flat though-beam sensors present versatile options for machine integration with no risk of cross-talk, when the sensors are arranged closely in arrays. For more information, visit www.sick.com. 18-23.qxp_Layout 1 22/10/2019 13:23 Page 422 Food & Drink International www.fdiforum.net PACKAGING SPOTLIGHT dŚĞh<ΖƐůĞĂĚŝŶŐƉĂĐŬĂŐŝŶŐƐƵƉƉůŝĞƌƚŽƚŚĞ ĨŽŽĚĂŶĚĚƌŝŶŬŝŶĚƵƐƚƌLJ͕ŽīĞƌŝŶŐĂǁŝĚĞ ƌĂŶŐĞŽĨƉĂĐŬĂŐŝŶŐƉƌŽĚƵĐƚƐŝŶĐůƵĚŝŶŐ͗ ŝƌ^ŚŽĐŬďŽƩůĞƉĂĐŬƐ WĂůůĞƚǁƌĂƉΘƐLJƐƚĞŵƐ ŽdžĞƐĨŽƌďŽƩůĞƐ >ĂďĞůƐ an employee-owned business Innovia & Wildcorn develop a fully recyclable & sustainable pack Innovia Films and the German snack manufacturer, Wildcorn have worked together to produce a fully recyclable and sustainable pack for their Wildcorn organic popcorn range. The joint project to establish a new sustainable packaging standard began soon after the launch of Innovia’s Propafilm Strata high barrier film. Tobias Enge, founder of Wildcorn, explains: “Our products are wholesome natural organic snacks, providing a healthier alternative to consumers. But as a consumer goods company we are responsible to look at the complete ecological impact of our product and packaging waste is one of the key challenges of our generation. Today’s emphasis on a ‘circular economy’ is very prominent so we decided to find a structure for our packaging that is fully recyclable.” The pack construction was tested by Interseroh and they confirmed that it was fully recyclable, awarding the pack the ‘Made for Recycling’ certification. For more information, www.innoviafilms.com. © Shutterstock/Sergey Ryzhov Total success for YPS at PPMA Total Show After attending the PPMA Total Show in October, Yorkshire Packaging Systems (YPS) has acquired and are now working on several exciting projects and enquiries. The Hugo Beck ‘Servo X’ and ‘Flexo X’ high speed side sealer models stood pride of place at the front of YPS’ exhibit, showing off their robust German manufacturing and intuitive controls and both generating a lot of interest from passing visitors. The newly-introduced Masterplat stretch wrapper from Robopac, for whom YPS are now a UK distributor, also amassed a lot of attention. The collection was completed by a complete sleeve sealing line and the company’s new pizza capping tabletop equipment. As well as a machinery offering, YPS showcased their unique, fully recyclable, OPRL-approved B-NAT bio-based shrink film, along with a variety of wrapped product samples. As a direct result of the PPMA show, YPS have now arranged many trials with new visitors who were impressed by B-NAT’s eco-friendly credentials. For more information, visit www.yps.co.uk. 18-23.qxp_Layout 1 22/10/2019 13:23 Page 5Food & Drink International 23 www.fdiforum.net PACKAGING SPOTLIGHT ®Reg. U.S. Pat. & Tm. Off. © Sealed Air Corporation (US) 2019. All rights reserved. Quite a lot actually. I know that sustainability challenges can seem daunting. But what if I told you that reducing plastic use, food waste and your carbon footprint can actually help grow your business? The CRYOVAC ® Brand Darfresh ® family of packaging solutions is designed to do just that, whilst completely surrounding and protecting your proteins so they last longer on the shelf too. But why take my word for it? See how you can make sustainability sell today. Visit www.sealedair.co.uk/darfresh-family to find out more. PATENT PENDING What do I know about the environment? Darfresh ® on TrayDarfresh ® DarffreshheshhDarfre therefore need to compete on shelf, so manufacturers are taking their packaging back to the drawing board. New product development is rife for packaging, from branding and design, right through to shape and materials. It’s an ideal way for food companies to convey their sustainability message and credentials to consumers. A package made from recycled material isn’t just versatility and great on-shelf appeal but, according to growth forecasts analysis from GMO, the stand-up pouch sprouts market will exceed $900 million by 2024. Therefore, machinery specialised in filling pouch packaging are becoming more commonplace, as are more specialised packaging machines in general. It’s a time of rapid innovation and development for food and drink packaging; changes that include every aspect of the value chain, from design and manufacture, right through to retail and recycling. © Shutterstock/ Zapp2Photo Durham Box digitally revamps BAD Co’s selection pack Durham Box has revamped BAD Co’s mixed multi-can beer pack. Inspired by American ale production, the beer brand needed an update on their selection pack, comprising of four different craft beer varieties. “Our reworked packaging for BAD Co has not only improved the digital quality of the artwork, but also streamlined production processes to reduce waste, improve efficiency and save the client money,” said Durham Box’s Paul Barker. “We started by cleaning up the existing artwork to enhance the can imagery on the box and create deeper blacks. We were able to reduce costs by removing any print from unseen areas of the pack. And by moving away from litho to the EFI Nozomi C18000 digital press, we were able to improve the production lead-time by two weeks. Keeping the entire process in-house with our latest kit, allows us to benefit from greater control on the entire process, whilst also reducing waste.” For more information, visit www.durhambox.co.uk. better for the environment, but it becomes a selling point, allowing manufacturers to stand out in an increasingly competitive marketplace. As important as sustainability is, manufacturers can’t afford to ignore innovative designs and packages that appeal to what modern consumers want. Millennials and generation Z lead busy lifestyles and often forgo traditional meals for quick and easy foods that can be eaten on-the-go. Pouch packaging is ideally suited for this market, particularly sprout packaging. Not only do they offer 18-23.qxp_Layout 1 22/10/2019 13:23 Page 624 Food & Drink International www.fdiforum.net FACILITIES MANAGEMENT F acilities management (FM) is wide ranging. While primarily facilities managers work to improve the efficiency of a processing plant, distribution centre or other facility, their role covers a variety of areas from health and safety to maintenance, cleaning, security, and the general day-to-day running of operations. Without FM, a facility simply cannot not run smoothly. Over the last few years there has been a rush to develop and implement digital technologies that will make facilities management more effective and efficient, mirroring the wider food and drink industry’s more confident entrance into the digital era. This includes a number of smart building initiatives that will change the facilities management profession to become more akin to a data provider and will likely see facilities managers know more about workplace on-goings than other departments. Facilities managers must therefore work closely with other teams to interpret data, share its insights and turn these into real-time actions. Smart building technology has had a major impact on FM. Using automated technologies including devices connected to the Internet of Things (IoT), smart building technology is being employed to automatically control operations such as heating, lighting and security as well as monitor environmental elements like humidity and temperature but also equipment performance. Constantly collecting data about a facility and its workers, when smart building technologies are connected to a workplace management system, data can be united in a single platform that is easily accessed by facilities managers and used to discover how to improve the running of a facility, save energy and reduce costs. Smart technologies also present the ability to remotely manage lights, HVAC systems, security cameras, locks, water use and more. IoT is a major topic of debate with facilities managers looking to install IoT devices - usually involving a network of sensors and other devices that send and receive data - in their buildings to increase automation and make their jobs easier by monitoring performance and highlighting potential issues that for humans are difficult to detect with hands on management. In FM IoT presents the possibility to understand in real time what is happening throughout a building, with each of its components and the operation, producing useful data for analytics. One of the main benefits of IoT is its role in enabling a preventative and predictive maintenance plan, rather than reactive, with the goal of reducing downtime in an industry producing, storing and moving highly sensitive products often prone to spoilage. IoT sensors and software can relay information on equipment, and monitor and analyse this to provide insight into machine health and performance and deliver alerts for any small changes in equipment, so that the source of a possible future failure can be found before it occurs, allowing for repairs to be planned effectively in a manner that will not hinder operations or lead to significant downtime. Machine Learning is helping here too in allowing building systems to collect and analyse data automatically to predict outcomes from experience, without being precisely programmed, enabling facilities managers to execute intelligent asset maintenance - a proactive maintenance approach based of the actual use of an asset. By sending automatic updates to facilities managers Machine Learning prevents unanticipated equipment breakdown by indicting when a potential issue is detected. The applications of IoT and sensors extends beyond maintenance plans, Smart and sustainable The collection, analysis and use of data has become a central aspect of facilities management, in the aim to optimise buildings and operations. 24-27.qxp_Layout 1 22/10/2019 13:26 Page 1Food & Drink International 25 www.fdiforum.net FACILITIES MANAGEMENT allowing for in depth environmental monitoring from light, temperature, humidity and CO2 to air pressure - all factors that can have a significant effect on staff health, well-being, productivity and goods. For instance studies show that when CO2 levels increase in a room, past 1000ppm, concentration decreases. IoT devices like CO2 meters, then, can estimate how many people are in a room and consequently indicate to the HVAC system that ventilation rate should be raised. Further uses for IoT and other smart building devices extends to asset tracking, inventory and order fulfilment in food warehouses as well as aiding a facilities manager’s responsibilities in security. For instance IoT can be amalgamated with surveillance cameras and smart locks as well as other physical security devices. Geofencing barriers in hand with IoT enabled locks and access tracking can alert security staff of breaches so they can respond more rapidly. Meanwhile other advances in security are seeing drones employed, robots experimented with for security patrols, the utilisation of electric equipment that is accessible through microchip implants, and wearables used to help facilities managers improve security of workers and data by limiting access to certain buildings or areas to specific people. Wearables can also be utilised by facilities managers to collect information on staff work patterns. Building information modelling (BIM), has also fast become a must-use technology for facilities managers. With BIM digital models of physical buildings are created and managed, allowing businesses to visualise the components of a space from the walls and windows to the placement of assets. While BIM originally came on the scene to help architects and contractors in designing new buildings, its use has extended to improve maintenance plans and space management strategies. With BIM, facilities managers are able to make data-based decisions on space and energy use and redesigns. Climate change and sustainability are also on the agenda for facilities managers, who are looking to improve environmental performance. Facilities managers are prioritising energy, water and waste efficiency initiatives as well as green building standards. Thanks to building and energy monitoring 26 Á © Shutterstock/ Zapp2Photo 24-27.qxp_Layout 1 22/10/2019 13:26 Page 226 Food & Drink International www.fdiforum.net FACILITIES MANAGEMENT systems as well as the IoT, facilities managers can gain deeper insight into, for instance, a facility’s asset-level energy consumption, to understand not only how much energy is being used but where it is being consumed to better manage a building and make cost savings. Something as simple as using LED lighting in processing areas can be highly beneficial on the road to boosting a food facilities environmental performance. Ideal for processing and packaging areas, LEDs have a longer lifespan, reducing downtime for replacing lighting, use around 75% less energy than other types of fixtures, creating significant savings long term, and perform well in cold temperatures that are required for many food processors, where for instance fluorescent lights are likely to malfunction. Pairing lights with occupancy sensors is also useful to automatically switch lights off in empty rooms, as well as sensors that turn lights on and off based on the amount of natural light available. Meanwhile skylights can be used to reduce energy consumption and are also said to create a better working environment for employees. Targeting water use is another topic of concern for the environmentally conscious facilities manager. Food plants of course use a large amount of water throughout the facility for activities from sanitation to processing. It is therefore important to establish a water conservation system, such as reusing process water for external sanitation, for instance for cleaning pallets and trucks. Also worth considering is a water catchment system to collect rainwater, pipe it into reservoirs and use it for sprinklers and irrigation, or installing flow meters on process equipment to make sure equipment is using a minimum amount of water. Moreover, reducing waste is too of key importance, which is seeing the stronger establishment of efficient waste disposal that minimises environmental impact of waste through closed loop solutions. © Shutterstock/ Wright Studio 24-27.qxp_Layout 1 22/10/2019 13:26 Page 3Food & Drink International 27 www.fdiforum.net FACILITIES MANAGEMENT Proven to improve performance in food cold stores whilst lowering operating costs Following the successful installation of 74 K2 Freezer Doors at one of the UK’s largest supermarket chains distribution centres, Klimate High Speed Doors, a trading division of BID Group Ltd, with over 25 years’ experience in the design, manufacture, installation, service and repair of high speed doors, unveil their improved revolutionary frost free high speed door, the ‘Klimate K2’. Reducing your carbon footprint is increasingly important these days but can be aided by using the Klimate K2 High Speed Freezer Door on Freezer and Chilled areas. The doors will help to improve traffic flow and minimise variation in temperatures which in turn will reduce costly energy loss and therefore improve the efficiency of your freezer. In addition to this the K2 Freezer door itself is energy efficient as it only requires a 20 Amp supply. The Klimate K2 High Speed Freezer Door is versatile as it can be installed on either the chilled, ambient or freezer side of the opening. All Klimate doors are engineered to the highest quality with a minimum of wearing parts and the K2 is no exception. The K2 is made in the UK of heavy galvanized steel and is then powder coated providing an easily cleanable surface with maximum strength to resist impact and shocks, which are inevitable in a busy through way. In addition to the fast operation speed other features include: An adjustable air defrost system which ensures the door remains ice and condensation free automatically switching off when the door is opened, reducing energy by up to 50% Hinged, re-settable breakaway tabs which reduce the risk of severe damage to the bottom rail in the event of impact. New generation, programmable diagnostic control panel with LED screen which shows the current status of the door Pays back on initial investment in less than two years compared to competitors’ doors Characteristic of all Klimate, high- speed doors, the simplistic nature of the door means that any minimal maintenance work can be quickly and easily undertaken in-house, drastically reducing down time and callout charges. Hardwearing, plastic re-settable end cassettes are fitted with a monitoring switch that stops the door if it is impacted. This in-turn will require a re- set which can be undertaken without tools by onsite maintenance personnel. The switch can also be programmed to activate alarms, beacons or even send a text message or email notifying that the door has been damaged. The location of any fault will be clearly displayed on the new generation control unit designed for high-speed doors. Any faults and stop-downs may generally then be handled in house with the support of the Klimate technical department who are on hand when the need arises to offer free guidance. For more information and to arrange a free site survey, visit www.klimate.co.uk, email sales@bidgroup.co.uk, or call +44(0) 870 6075050. Klimate K2 High Speed Freezer Door 24-27.qxp_Layout 1 22/10/2019 13:26 Page 428 Food & Drink International www.fdiforum.net LOGISTICS T he importance of logistics in the food sector has only grown as consumer trends and demands - from online orders and quicker deliveries to intensifying globalisation and the booming crave for fresh, organic and local perishables - put more pressure on food companies and the supply chain. Logistics is now central to the success of food companies and can be the distinguishing factor that places a business ahead of the competition. Without effective and timely transport and delivery of products and ingredients, whether it be to a retailer or processing facility, it is easy to develop a poor reputation and lose customers. Logistics is getting smarter and more transparent - a key ask in the food industry today. Whether utilising robotics in warehouses or computerised tracking, new levels of visibility have been brought to food logistics. Monitoring technologies in particular are important and being used to not only discover efficiencies but create more transparency and traceability by presenting end to end visibility to ensure products do not deteriorate during their journey. Thanks to the Internet of Things (IoT) and its sensors, distribution firms and customers are able to track products in transit in real time and a significant amount of information on for instance temperatures, humidity, pressure, movements and tampering can be recorded through all stages of a journey, and alerts made to any variations, enabling careful inventory control that is vital in avoiding spoilage, damage and contamination that can violate food safety legislation. This is of key importance as around a third of food globally is wasted as a result of spoiling in transit or being thrown out. With IoT technologies product information can be gained quickly and reliably. Further, technology using freight tracking and satellite data is allowing customers to see when a cargo ship has arrived, docked and is being unloaded, which holds the ability to reduce port delays and the wasted time in which trucks wait at ports for an unknown pickup time. Sensors are being well utilised by risk management tools in the currently high Central to success As demand continues to reach unprecedented global levels, logistics is key to ensure the success of the food industry. 28-30.qxp_Layout 1 22/10/2019 13:30 Page 1Food & Drink International 29 www.fdiforum.net LOGISTICS in demand cold chain, which has stepped into a new world defined by sophisticated temperature tracking and monitoring with IoT, to prove the quality of sensitive products. These tools present data on product status collected from connected sensors which analyse the storage conditions that can impact product integrity. Usefully then, in the case of a late delivery, where a lack of demonstratable information on quality of goods may in the past see them refused and disposed of as a precaution, with these new tools customers can be informed in real time of any delays and note the consistent conditions that have kept them useable and sellable. Schedules can also usefully be altered across the supply chain to meet live time delays. For instance a manufacturer can adjust their production schedule. The use of wireless monitoring and IoT extends into the warehouse. With IoT sensors and RFID tags around the warehouse and on goods, constant real- time details on an item’s status and position are relayed, allowing for improved visibility and stock accuracy. This tracking can also be utilised to discover patterns and demand trends, enabling warehouse users to be more proactive regarding stock held in the future, and can help prevent incidents like overstocking. Predictive analytics and data collection meanwhile are also enabling forward planning in logistics. Analytics is growing as firms look to improve forecast accuracy, optimise transportation performance, and boost tracking across the supply chain. The utilisation of big data is of key importance, for example in streamlining and optimising costs. Fleet managers can use big data solutions and routing technology to improve delivery routes and as a result costs, integrating data from numerous sources from weather reports to road maintenance data and vehicle maintenance schedules so that vehicles can always take the ideal route and reroute as necessary. With the time sensitivity of the food industry this tool is vital. Routing technology and big data are making distributors more competitive. When embracing route optimisation © Shutterstock/Travel mania 30 Á 28-30.qxp_Layout 1 22/10/2019 13:30 Page 2Next >